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Learning Objectives
• Describe how work should move
through the workplace.
• Discuss how to design work processes.
• State the interrelationship between
facilities design and process design.
• List factors to be considered when
planning a master schedule.
• Plan a master schedule for the
implementation of a project.
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Learning Objectives
• Define task analysis, work
simplification, job rotation, job
enlargement, and job enrichment.
• List factors to be considered when
writing a work schedule for employees.
• Prepare an employee schedule.
• Define production.
• Describe each of the steps in production
planning.
• Discuss what types of tools are used to
control production.
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The Flow of Work
• Workflow
– The way in which
people and products
move through a
workplace.
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The Flow of Work
• Facilities Design
– The layout of a workplace (including
traffic patterns), which affects the
flow of people, goods, and services
within a designated space.
– "Straight-line" traffic flow
• Often impractical because of great
distances between ends
• Compartmentalizes workers
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Kitchen with a "straight-line" traffic
flow
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"Straight-line" traffic pattern may be
modified to eliminate cross-traffic
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The Flow of Work
• Facilities Design
– Avoiding multiple intersections
•Space is often too limited for a
linear traffic flow
•Traffic patterns should be designed
to eliminate or reduce intersections
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Kitchen with multiple intersections
Kitchen with a "no-intersection" traffic
flow
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The Flow of Work
• Facilities Design
– Traffic patterns for service products
•Clinical practices
•Event planning
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The Flow of Work
• Process Design
– The methods and procedures used to
facilitate the movement of people, work,
and materials through space and time.
– Storage in storerooms or at point of service
– Form in which materials arrive
– Economy of Scale - A concept that it is
more efficient to complete a task once on a
large scale versus repeating the same task
on a smaller scale to reach the same output
level.
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The Flow of Work
• The movement of work through
time
– Master Schedule - A time-based
written outline, usually for complex or
non-routine jobs, that plans the
movement of work across time and is
used to follow progress and keep
work on time.
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The Flow of Work
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The Flow of Work
• The movement of work through
time
– Gantt Chart - A two dimensional
diagram of a master schedule on
which activities are listed on the left
side of the figure and times are
represented across the top.
– It depicts the movement of work
through time.
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The Flow of Work
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The Flow of Work
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Job Design
• Job Reengineering
– The process of restructuring jobs to fit the
needs of employees and to respond to the
continuously changing environment,
technology, and needs of society.
• Older techniques: task analysis and
work simplification
• More recent innovations: job rotation,
job enlargement, and job enrichment
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Job Design
• Task Analysis
– The process of observing, in detail,
each aspect of a job to determine
whether increases in efficiency or
safety can be achieved.
– Done for 2 reasons:
• To identify inefficiencies that can be
minimized or eliminated
• To identify and eliminate those activities
that could lead to worker injury
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Job Design
• Work Simplification
– The process of changing how a job is
performed to decrease the energy
expenditure and increase the output
of a worker.
– Original emphasis was to reduce
number of motions in a task
– Useful for improving efficiency of
manual tasks in foodservice
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Job Design
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Job Design
• Work Simplification
– Ergonomics - The physical aspects of work
and movement; how movement relates to
the performance of a task.
– Important for reducing risk of work-related
injury, such as repetitive stress injury
• Repetitive Stress Injury - Physical harm
resulting from the strain of repeatedly doing the
same task in the same way.
– ex: meal plating assembly line
arrangements...
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Job Design
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Job Design
• Work Simplification
– The Occuaptional Safety and Health
Administration has an ergonomics
page at
http://www.osha.gov/SLTC/ergonomi
cs/index.html
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Job Design
• Job Rotation
– The practice of having workers do
different jobs at different times to
improve job satisfaction and minimize
the potential for repetitive stress
injury.
– Cross-Training - Preparing
employees to perform various jobs
within a work setting.
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Job Design
• Job Enlargement
– The practice of increasing the tasks
done within a specific job; increasing
the number and types of skills
workers use in their jobs.
– Multi-Skilling - The process
whereby workers learn to perform
new tasks and to develop techniques
that, in turn, enlarge their jobs.
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Job Design
• Job Enrichment
– The practice of adding variety and,
simultaneously, increasing the
knowledge required to do a job.
– Job enrichment activities should be
designed to respond to each
employee’s unique characteristics.
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Labor Schedules
• Labor Schedule
– A management tool used to designate the
hours and days each employee is to work.
• The schedule is a management tool
• Manager's and then workers' needs
should be considered
• Adjustments can be made at workers'
request when possible
• Using scheduling to punish or reward
can undermine credibility
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Labor Schedules
• Schedule writing begins with a grid
– ex: Figure 12.7...
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Labor Schedules
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Labor Schedules
• How to write the schedule:
– Enter days off for all employees
– Enter hours for full-time employees
– Add guaranteed hours for part-time
and short-hour employees
– Add casual employee hours as
needed to complete schedule
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Labor Schedules
• Evaluate cost-effectiveness
• If possible, schedule days off
consecutively
• Employees may be able to
schedule their own hours if
requirements are established
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Production and Productivity
• Production
– The process of converting inputs into
products such as goods, services, or ideas.
• Planning production
– 3 basic steps:
• Determine what will be produced and how much
• Create production schedule
• Communicate with the workforce
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Production and Productivity –
Planning Production
• Forecasting - A tool used to predict
the quantities of product needed.
• Methods of forecasting:
– Subjective Forecasting - A forecasting
method that uses information, experience,
and intuition to determine the amount of
product needed.
– Manual Tally - The physical counting of
orders received to determine production
needs.
• Often used in hospitals for patient trays
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Production and Productivity –
Planning Production
• Methods of forecasting:
– Percentage Forecasting Determining how much of a specific
item is needed as a percentage of the
total number of items needed.
• Padding - The practice of ordering and
producing more product than is actually
needed in order to avoid shortages.
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Production and Productivity –
Planning Production
• Methods of forecasting:
– Computer Forecasting - Using
computer-generated forecasts to
determine production needs.
• Accuracy is dependent on reliable
historical data.
• If data is faulty, computer forecasting will
give equally faulty results.
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Production and Productivity –
Planning Production
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Production and Productivity –
Planning Production
• Production scheduling
– Production Schedule - A document
that specifies what is produced, how
much, at what time, and by whom.
• Similar to master schedule, but is
typically less formal and covers shorter
period of time
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Production and Productivity –
Planning Production
• Production Meetings - Planned
or scheduled times when
employees and managers gather
to discuss production issues.
– Often used for information
dissemination and for problem
solving.
– Major benefit = two-way
communication
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Production and Productivity
• Production Control
– The process of monitoring production
during and after it has occurred to
determine if plans are being met and
to make adjustments as required.
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Production and Productivity –
Production Control
• Production controls in foodservice
– Resource: The “Virtual” Nutrition Center at
http://www.martindalecenter.com/Nutrition.
html
– Recipes
• Standardized Recipe - A production control that
gives a known quantity of known quality
ingredients to establish amounts needed to
continuously reproduce the same high-quality
product.
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Production and Productivity –
Production Control
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Production and Productivity –
Production Control
• Production controls in foodservice
– Yield - The amount of a product available
for consumption from a specified quantity of
ingredients after adjusting for losses that
occur during production and service.
• As Purchased (AP) - The amount of a product
(food item) acquired before any production loss
has occurred.
• Edible Portion (EP) - The amount of food that
can be consumed after accounting for preparation
and/or cooking losses.
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Production and Productivity –
Production Control
• Production controls in foodservice
– Portion Control - A form of
production control to regulate serving
size.
• Pre-portioning food
• Scoring food
– ex: Figure 12.9...
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Production and Productivity –
Production Control
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Production and Productivity –
Production Control
• Production controls in foodservice
– Portion Control
• Weighing food
• Using standard serving utensils
– Temperature control
– Tasting food before service to
customers
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Conclusion
• How work moves through the
workplace is dependent on both
the physical layout of the
workplace and on the processes
delineating how the work is done.
Facilities and process design are
interdependent—that is, alterations
in one will inevitably lead to
changes in the other.
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Conclusion
• For major projects, a master schedule is
used for time management to assure
that the work is proceeding according to
plan.
• Individual jobs are designed using task
analysis, work simplification, job
rotation, job enlargement, and job
enrichment techniques, all of which
may make a positive contribution to the
employees’ level of satisfaction with
their jobs.
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Conclusion
• Employee work schedules are a
management tool that should be used
to meet both the needs of management
and those of employees.
• Production planning tools include a
forecasting method, production
schedules, and production meetings.
• Production controls are used to direct
the conversions of inputs into products
that are uniform and reproducible.
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HACCP: A State-of-the-Art
Approach to Food Safety
• What is HACCP? HACCP involves seven
principles:
– Analyze hazards.
– Identify critical control points.
– Establish preventive measures with critical
limits for each control point.
– Establish procedures to monitor the critical
control points.
– Establish corrective actions to be taken
when monitoring shows that a critical limit
has not been met.
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HACCP: A State-of-the-Art
Approach to Food Safety
• HACCP principles (cont.):
– Establish procedures to verify that
the system is working properly.
– Establish effective recordkeeping to
document the HACCP system.
• Need for HACCP
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HACCP: A State-of-the-Art
Approach to Food Safety
• Advantages:
– focuses on identifying and preventing
hazards from contaminating food
– is based on sound science
– permits more efficient and effective
government oversight, primarily because
the recordkeeping allows investigators to
see how well a firm is complying with food
safety laws over a period rather than how
well it is doing on any given day
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HACCP: A State-of-the-Art
Approach to Food Safety
• Advantages:
– places responsibility for ensuring food
safety appropriately on the food
manufacturer or distributor
– helps food companies compete more
effectively in the world market
– reduces barriers to international trade
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